Mask for deposition, apparatus for manufacturing display apparatus having the same, and method of manufacturing display apparatus with manufacturing display apparatus having mask for deposition

ABSTRACT

A deposition mask includes a deposition pattern through which a deposition material passes and a distal end extended in a length direction of the deposition mask from the deposition pattern. The distal end includes a dummy pattern between a clamping groove and the deposition pattern in the length direction. The clamping groove and the dummy pattern are provided in plural along a second direction crossing the length direction. In the length direction of the deposition mask, the number of clamping grooves and dummy patterns correspond to each other, the clamping grooves respectively overlap a corresponding dummy pattern, a distal end area at which clamping grooves overlap the corresponding dummy pattern defines a second area of the distal end, and a distal end area at which the clamping grooves do not overlap the corresponding dummy pattern defines a first area of the distal end to which a clamp is applied.

This application claims priority to Korean Patent Application No.10-2016-0024718, filed on Feb. 29, 2016, and all the benefits accruingtherefrom under 35 U.S.C. §119, the contents of which in their entiretyare herein incorporated by reference.

BACKGROUND

1. Field

One or more embodiments relate to an apparatus and a method, and moreparticularly, to a mask for deposition, an apparatus to manufacture adisplay apparatus, and a method of manufacturing the display apparatususing the apparatus to manufacture a display apparatus.

2. Description of the Related Art

Mobile electronic apparatuses have been widely used. The mobileelectronic apparatuses include a relatively small electronic apparatus,such as a mobile phone and a tablet personal computer (“PC”).

Since such a mobile electronic apparatus supports various functions, themobile electronic apparatus includes a display apparatus to provide auser with visual information such as an image and a motion picture. Ascomponents of the mobile electronic apparatus to drive the displayapparatus thereof are minimized in size, the display apparatus becomesmore important in the mobile electronic apparatus. A structure, in whichthe display apparatus is bent at a predetermined angle from a flat statethereof, is being developed.

SUMMARY

One or more embodiments include a mask for deposition, an apparatusincluding the mask for deposition to manufacturing a display apparatus,and a method of manufacturing the display apparatus using the apparatusincluding the mask for deposition to manufacturing a display apparatus.

Additional features will be set forth in part in the description whichfollows and, in part, will be apparent from the description, or may belearned by practice of the presented embodiments.

According to one or more embodiments, a deposition mask for depositing adeposition material on a substrate includes a deposition pattern unitincluding a plurality of deposition pattern holes through which thedeposition material passes to the substrate; and a distal end extendedin a first direction of the deposition mask from the deposition patternunit to a distal edge of the deposition mask. The distal end includes aclamping groove open at the distal edge of the deposition mask; and adummy pattern unit disposed between the clamping groove and thedeposition pattern unit in the first direction of the deposition mask.The clamping groove and the dummy pattern unit are provided in pluralalong a second direction crossing the first direction of the depositionmask. In the first direction of the deposition mask, a portion of eachclamping groove overlaps a corresponding dummy pattern unit, in thesecond direction of the deposition mask, the number of the clampinggrooves and the number of the dummy pattern units correspond to eachother,

an area of the distal end at which the portion of the distal end doesnot overlap the corresponding dummy pattern unit defines a first area ofthe distal end to which a clamp is applied, and an area of the distalend at which the portion of each clamping groove overlaps thecorresponding dummy pattern unit defines a second area of the distalend.

According to one or more embodiments, the dummy pattern unit may includea plurality of dummy pattern holes, and a shape of one of the pluralityof dummy pattern holes may correspond to a shape of one of the pluralityof deposition pattern holes.

According to one or more embodiments, the dummy pattern unit may includea plurality of dummy pattern holes, and a shape of one of the pluralityof dummy pattern holes may be different from a shape of one of theplurality of deposition pattern holes.

According to one or more embodiments, in the first direction of thedeposition mask, the dummy pattern unit may include a first pattern unitand a second pattern unit spaced apart from each other. Each of thefirst and second pattern units may include a plurality of dummy patternholes.

According to one or more embodiments, an apparatus for manufacturing apattern on a substrate of a display apparatus includes a deposition maskframe assembly facing the substrate, and a deposition source facing thedeposition mask frame assembly to dispose the deposition mask frameassembly between the substrate and the deposition source. The depositionmask frame assembly includes a frame having an opening at a centerportion thereof, a deposition mask which is installed on the frame toface the substrate, a first of the deposition mask extended in a firstdirection, and a support of which a length thereof extends in a seconddirection crossing the first direction and across the opening of theframe, the support overlapping a portion of the deposition mask, andsupporting the deposition mask which is installed on the frame. Thedeposition mask is extendable along the first direction thereof by aforce applied thereto by a clamp attached to the deposition mask. Thedeposition mask includes a deposition pattern unit having a plurality ofdeposition pattern holes through which a deposition material for formingthe pattern passes to the substrate, and a distal end to which the clampis attached, the distal end extended in the first direction of thedeposition mask from the deposition pattern unit to a distal edge of thedeposition mask. The distal end includes a clamping groove open at thedistal edge of the deposition mask; and a dummy pattern unit disposedbetween the clamping groove and the deposition pattern unit in the firstdirection of the deposition mask. The clamping groove and the dummypattern unit are provided in plural along the second direction. In, thefirst direction of the deposition mask, a portion of each clampinggroove overlaps a corresponding dummy pattern unit, in the seconddirection of the deposition mask, the number of the clamping grooves andthe number of the dummy pattern units correspond to each other, an areaof the distal end at which the portion of distal end does not overlapthe corresponding dummy pattern unit defines a first area of the distalend to which a clamp is applied, and an area of the distal end at whichthe portion of each clamping groove overlaps the corresponding dummypattern unit defines a second area of the distal end.

According to one or more embodiments, the dummy pattern unit may includea plurality of dummy pattern holes, and a shape of one of the pluralityof the dummy pattern holes may correspond to a shape of one of theplurality of the deposition pattern holes.

According to one or more embodiments, the dummy pattern unit may includea plurality of dummy pattern holes, and a shape of one of the pluralityof dummy pattern holes may be different from a shape of one of theplurality of deposition pattern holes.

According to one or more embodiments, in the first direction of thedeposition mask, the dummy pattern unit may include a first dummypattern unit and a second dummy pattern unit spaced apart from eachother. Each of the first dummy pattern unit and a second dummy patternunit may include a plurality of dummy pattern holes.

According to one or more embodiments, the deposition mask frame assemblymay further include a welding portion to couple the frame and thedeposition mask to each other. The welding portion is disposed at thedistal end of the deposition mask.

According to one or more embodiments, in the first direction of thedeposition mask, the welding portion may be installed between thepattern unit and the dummy pattern unit.

According to one or more embodiments, a method of manufacturing adisplay apparatus having a pattern on a substrate includes inserting thesubstrate and a deposition mask assembly into an inside of a depositionchamber, aligning the substrate and the deposition mask frame assemblywith each other, and depositing on the substrate a deposition materialfor forming the pattern by ejecting the deposition material from adeposition source and passing the ejected deposition material throughthe deposition mask frame assembly to the substrate The deposition maskframe assembly includes a frame having an opening at a center portionthereof, a deposition mask which is installed on the frame to face thesubstrate, a length of the deposition mask extended in a firstdirection, and a support of which a length thereof extends in a seconddirection crossing the first direction and across the opening of theframe, the support overlapping a portion of the deposition mask andsupporting the deposition mask which is installed on the frame. Thedeposition mask is extendable along the first direction thereof by aforce applied thereto by a clamp attached to the deposition mask. Thedeposition mask includes a pattern unit including a plurality ofdeposition pattern holes through which the ejected deposition materialpasses, and a distal end to which the clamp is attached, the distal endextended in the first direction of the deposition mask from thedeposition pattern unit to a distal edge of the deposition mask. Thedistal end includes a clamping groove open at the distal edge of thedeposition mask and a dummy pattern unit disposed between the clampingunit and the pattern unit in the first direction of the deposition mask.The dummy pattern unit and the clamping groove are disposed in pluralalong the second direction. In the first direction of the depositionmask, a portion of each clamping groove overlaps a corresponding dummypattern unit, in the second direction of the deposition mask, the numberof the clamping grooves and the number of the dummy pattern unitscorrespond to each other,

an area of the distal end at which the portion of the distal end doesnot overlap the corresponding dummy pattern unit defines a first area ofthe distal end to which a clamp is applied, and an area of the distalend at which the portion of each clamping groove overlaps thecorresponding dummy pattern unit defines a second area of the distalend.

According to one or more embodiments, the dummy pattern unit may includea plurality of dummy pattern holes, and a shape of one of the pluralityof the dummy pattern holes may correspond to a shape of one of theplurality of deposition pattern holes.

According to one or more embodiments, the dummy pattern unit may includea plurality of dummy pattern holes, and a shape of one of the pluralityof the dummy pattern holes may be different from a shape of one of theplurality of deposition pattern holes.

According to one or more embodiments, in the first direction of thedeposition mask, the dummy pattern unit may include a first dummypattern unit and a second dummy pattern unit spaced apart from eachother. Each of the first and second dummy pattern units may include aplurality of dummy pattern holes.

According to one or more embodiments, the deposition mask frame assemblymay further include a welding portion which couples the frame and thedeposition mask to each other. The welding portion is disposed at thedistal end of the deposition mask.

According to one or more embodiments, in the first direction of thedeposition mask, the welding portion may be disposed between the patternunit and the dummy pattern unit.

BRIEF DESCRIPTION OF THE DRAWINGS

These and/or other features will become apparent and more readilyappreciated from the following description of the embodiments, taken inconjunction with the accompanying drawings in which:

FIG. 1 is a perspective view schematically illustrating an exemplaryembodiment of a deposition mask according to the invention;

FIG. 2 is a top plan view illustrating a conventional deposition mask;

FIG. 3 is a top plan view illustrating the deposition mask of FIG. 1;

FIG. 4 is a graph illustrating a height of a wrinkle of the conventionaldeposition mask of FIG. 2;

FIG. 5 is a graph illustrating a height of a wrinkle of the depositionmask of FIG. 3;

FIG. 6 is a top plan view illustrating another exemplary embodiment of adeposition mask according to the invention;

FIG. 7 is a top plan view illustrating still another exemplaryembodiment of a deposition mask according to the invention;

FIG. 8 is a perspective view schematically illustrating an exemplaryembodiment of a deposition mask frame assembly including the depositionmask of FIG. 1;

FIG. 9A is a cross-sectional view schematically illustrating anexemplary embodiment of a manufacturing apparatus including thedeposition mask frame assembly of FIG. 8 for manufacturing a displayapparatus;

FIG. 9B is an enlarged cross-sectional view of portion P of themanufacturing apparatus including the deposition mask frame assembly ofFIG. 8;

FIG. 10 is a top plan view illustrating the display apparatusmanufactured by the manufacturing apparatus of FIG. 9A and a method ofmanufacturing the display apparatus using the manufacturing apparatus,according to the invention; and

FIG. 11 is a cross-sectional view taken along line XI-XI of FIG. 10.

DETAILED DESCRIPTION

The exemplary embodiments may have different forms and embodiments andshould not be construed as being limited to the descriptions set forthherein. Accordingly, the exemplary embodiments are merely describedbelow, by referring to the figures, to explain features of the presentdescription.

It will be understood that although the terms “first,” “second,” etc.,may be used herein to describe various components, these componentsshould not be limited by these terms. These components are only used todistinguish one component from another.

It will be understood that when an element is referred to as being “on”another element, it can be directly on the other element or interveningelements may be present therebetween. In contrast, when an element isreferred to as being “directly on” another element, there are nointervening elements present.

As used herein, the singular forms “a,” “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising” used herein specify the presence of stated featuresor components, but do not preclude the presence or addition of one ormore other features or components.

Sizes of elements in the drawings may be exaggerated for convenience ofexplanation. In other words, since sizes and thicknesses of componentsin the drawings are arbitrarily illustrated for convenience ofexplanation, the following embodiments are not limited thereto. When acertain embodiment may be implemented differently, a specific processorder may be performed differently from the described order. Forexample, two consecutively described processes may be performedsubstantially at the same time or performed in an order opposite to thedescribed order.

In the following examples, the x-axis, the y-axis and the z-axis are notlimited to three axes of the rectangular coordinate system, and may beinterpreted in a broader sense. For example, the x-axis, the y-axis andthe z-axis may be perpendicular to one another, or may representdifferent directions that are not perpendicular to one another.

As used herein, the term “and/or” includes any and all combinations ofone or more of the associated listed items. Expressions, such as “atleast one of,” when preceding a list of elements, modify the entire listof elements and do not modify the individual elements of the list.

Furthermore, relative terms, such as “lower” or “bottom” and “upper” or“top,” may be used herein to describe one element's relationship toanother element as illustrated in the Figures. It will be understoodthat relative terms are intended to encompass different orientations ofthe device in addition to the orientation depicted in the Figures. Forexample, if the device in one of the figures is turned over, elementsdescribed as being on the “lower” side of other elements would then beoriented on “upper” sides of the other elements. The exemplary term“lower,” can therefore, encompasses both an orientation of “lower” and“upper,” depending on the particular orientation of the figure.Similarly, if the device in one of the figures is turned over, elementsdescribed as “below” or “beneath” other elements would then be oriented“above” the other elements. The exemplary terms “below” or “beneath”can, therefore, encompass both an orientation of above and below.

“About” or “approximately” as used herein is inclusive of the statedvalue and means within an acceptable range of deviation for theparticular value as determined by one of ordinary skill in the art,considering the measurement in question and the error associated withmeasurement of the particular quantity (i.e., the limitations of themeasurement system). For example, “about” can mean within one or morestandard deviations, or within ±30%, 20%, 10% or 5% of the stated value.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this disclosure belongs. It willbe further understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the relevant art and thepresent disclosure, and will not be interpreted in an idealized oroverly formal sense unless expressly so defined herein.

Exemplary embodiments are described herein with reference to crosssection illustrations that are schematic illustrations of idealizedembodiments. As such, variations from the shapes of the illustrations asa result, for example, of manufacturing techniques and/or tolerances,are to be expected. Thus, embodiments described herein should not beconstrued as limited to the particular shapes of regions as illustratedherein but are to include deviations in shapes that result, for example,from manufacturing. For example, a region illustrated or described asflat may, typically, have rough and/or nonlinear features. Moreover,sharp angles that are illustrated may be rounded. Thus, the regionsillustrated in the figures are schematic in nature and their shapes arenot intended to illustrate the precise shape of a region and are notintended to limit the scope of the present claims.

Reference will now be made in detail to embodiments, examples of whichare illustrated in the accompanying drawings, where like referencenumerals refer to like elements throughout.

As a component to drive a display apparatus within a mobile apparatus,an electrode includes an organic material or a metal material. Theelectrode of the display apparatus is manufactured by using a vacuumdeposition method of forming a thin film by depositing a material on asubstrate in a vacuum environment. The vacuum deposition method includesplacing inside a vacuum chamber, a substrate on which an organic thinfilm is to be formed, attaching to the substrate, a mask for depositionwhich includes the same pattern as the organic thin film to be formed,vaporizing a source organic material by using a deposition source, andthen depositing the vaporized organic material onto the substrate viathe mask for deposition.

In order to manufacture a relatively high resolution display apparatus,the substrate and the frame are held in relatively close-contact duringa manufacturing process to avoid generating an undesirable shadowphenomenon thereby.

A mask for deposition, which is used in a deposition method process forforming a thin film, has become relative thinner to realize a highresolution of a display apparatus. However, when opposite ends of themask are extended and then are welded to a frame during the depositionmethod process, wrinkles are formed between a portion of the mask towhich a tensile force is applied and another portion of the mask towhich the tensile force is not applied. If the wrinkles are formed inthe mask for deposition, the substrate on which the thin film is to beformed and the mask for deposition are not in close contact with eachother, and thus the shadow phenomenon occurs.

Before a mask for deposition (hereinafter, “mask for deposition” isreferred to as “deposition mask,” for example, a deposition mask 120 ofFIG. 1) according to an embodiment of the invention is described, adeposition mask 120P according to the prior art will be brieflydescribed with reference to FIG. 2.

FIG. 2 is a top plan view of the deposition mask 120P according theprior art.

Referring to FIG. 2, the deposition mask 120P is used in a process ofdepositing an organic material or a metal material on a substrate (forexample, a substrate 11 of FIG. 9A) of a display apparatus. In order toavoid a shadow phenomenon, while both distal ends 120P_e of thedeposition mask 120P are clamped such as by a clamp, the deposition mask120P is extended to be in an extension state thereof. While thedeposition mask 120P is in the extension state, the extended depositionmask 120P is welded on a frame (for example, a frame 110 of FIG. 8).Here, the “shadow phenomenon” may be referred to as a phenomenon tocause a display defect to the substrate 11 when the substrate 11 and thedeposition mask 120P are not in close contact with each other such thata gap is formed between the substrate 11 and the deposition mask 120P,and the gap allows a deposition material to be deposited on an area ofthe substrate 11 other than a predetermined effective area of thesubstrate 11.

In detail, the clamp clamps the distal ends 120P_e of the depositionmask 120P in a clamped state thereof before the deposition mask 120P iswelded to the frame 110. While the distal ends 120P_e is in the clampedstate, then the deposition mask 120P is extended by applying a tensileforce (F in FIG. 2) to portions of the deposition mask 120P in adirection in which the distal ends 120P_e of the deposition mask 120Pare away from a center of the deposition mask 120P. For example, thetensile force (F) may be applied to the deposition mask 120P along alength dimension thereof, relative to a center of the length dimension.Thereafter, while the tensile force is applied to the deposition mask120P, the distal ends 120P_e of the deposition mask 120P are placed onthe frame 110, and the frame 110 and the deposition mask 120P are weldedto each other such as according to a welding process.

Referring to FIG. 2, the frame 110 and the deposition mask 120P may becoupled to each other at a welding portion 140P of the deposition mask120P. Here, the welding portion 140P is represented by a broken linesince the deposition mask 120P illustrated in FIG. 2 is not welded tothe frame 110 and is separate therefrom. After the welding process,portions of the distal ends 120P_e of the deposition mask 120P, whichprotrude further than edges of the frame 110, are removed. In detail,the portions of the distal ends 120P_e of the deposition mask 120P,which are disposed outside the welding portion 140P relative to thecenter of the deposition mask 120P, may be removed.

An area of the respective distal ends 120P_e of the deposition mask120P, which is clamped by the clamp, is referred as a first area of thedeposition mask 120P. In the top plan view of FIG. 2, the depositionmask 120P defines a length dimension thereof (vertical in FIG. 2) largerthan a width dimension thereof (horizontal in FIG. 2). A direction inwhich the length dimension of the deposition mask 120P is extended, isreferred to as a first direction (Y axis direction). The above-describedfirst area and first direction of the deposition mask 120P may also beused in the exemplary embodiment of the deposition mask 120 of FIG. 1according to the invention.

FIG. 1 is a perspective view schematically illustrating an exemplaryembodiment of the deposition mask 120 according to the invention, FIG. 2is a top plan view illustrating a deposition mask 120P according to theprior art; and FIG. 3 is a top plan view illustrating the depositionmask 120 of FIG. 1.

Referring to FIG. 1, the deposition mask 120 may include a depositionpattern unit 121 (hereinafter referred to as a “pattern unit 121”), aclamping groove 122 provided in plural and a dummy pattern unit 123provided in plural. In the top plan view, the clamping groove 122 isrecessed from a distal edge of the deposition mask 120 toward the dummypattern unit 123.

Since the deposition mask 120 of FIG. 1 is not combined with a frame 110and disposed separate from the frame 110, a welding portion 140 is notformed on the deposition mask 120, and thus a position at which thewelding portion 140 would be formed is indicated by a broken line asillustrated in FIG. 1. The welding portion 140 will be described indetail later together with a manufacturing apparatus 10, whichmanufactures a display apparatus, with reference to FIG. 8.

The pattern unit 121 includes a plurality of deposition pattern holes121_h (hereinafter referred to as “pattern holes 121_h) through which adeposition material passes to a substrate which will be described later.The pattern holes 121_h extend through an entire thickness of thedeposition mask 120. The plurality of pattern holes 121_h may have asame or similar shape as each other. FIG. 1 illustrates that theplurality of pattern holes 121_h have a rectangular shape in the topplan view. However, the invention is not limited thereto. That is, theplurality of pattern holes 121_h may have various shapes in the top planview, such as a polygon, a circle or an ellipse. However, an exemplaryembodiment in which the plurality of pattern holes 121_h having therectangular shape will be explained hereinafter for convenience.

A distal end 120_e may include an entire width of the deposition mask120 from the distal edge of the deposition mask 120 to the dummy patternunit 123. Referring to the above description, an area of the respectivedistal ends 120_e of the deposition mask 120, which is clamped by aclamp, is referred as a first area of the deposition mask 120. Portionsof the distal ends 120_e of the deposition mask 120 at opposing sides ofthe clamping groove 122 and extending in the first direction aredisposed in the first area.

The clamping groove 122 may be in a second area of the respective distalends 120_e of the deposition mask 120 which is not clamped by a clampwhen the deposition mask 120 is extended. That is, the second area ofthe respective distal ends 120_e is a remaining area of the respectivedistal ends 120_e excluding the first area thereof, which is describedabove with reference to FIG. 2. The distal ends 120_e of the depositionmask 120 are opposite to each other with respect to the pattern unit121. Generally, an inside circumference of the clamping groove 122 iscurved to reduce or effectively prevent damage or deformation of thedeposition mask 120, which is caused by the tensile force (F) which isapplied to the deposition mask 120 to extend the deposition mask 120.The first area may alternate with second areas in the second direction.

The dummy pattern unit 123 may be between the pattern unit 121 and therespective distal ends 120_e of the deposition mask 120 where each ofthe distal ends 120_e includes the first area and the second areadescribed above. The dummy pattern unit 123 may include a plurality ofdummy pattern holes 123_h. The plurality of dummy pattern holes 123_hmay not be used for material deposition. In the top plan view, theplurality of dummy pattern holes 123_h may have a shape corresponding tothe shape of the plurality of pattern holes 121_h. That is, theplurality of dummy pattern holes 123_h may have various shapes in thetop plan view, such as a polygon, a circle and an ellipse, like theshape of the plurality of pattern holes 121_h. Hereinafter, an exemplaryembodiment in which the plurality of dummy pattern holes 123_h having arectangular shape, will be described in detail, for convenience.

Referring to FIG. 3, the deposition mask 120 defines a length dimensionthereof (first direction or Y axis direction in FIG. 1) larger than awidth dimension thereof (second direction or X axis direction in FIG.1). The first area of the distal ends 120_e, which is clamped by theclamp, includes an area corresponding to a reference region “A” and anarea corresponding to the first direction (Y axis direction), and thesecond area of the distal ends 120_e, which is not clamped by the clamp,includes an area corresponding to a reference region “B” and an areacorresponding to the first direction (Y axis direction).

For the deposition mask 120, a distal end 120_e may include an entirewidth of the deposition mask 120 from a distal edge of the depositionmask 120 such as to the dummy pattern unit 123 (e.g., where “A” and “B”are indicated). The distal end 120_e may include the dummy pattern unit123. The second area may be defined by an entire length of the distalend 120_e at which the clamping groove 122 overlaps the clamping groove122 in the length direction of the deposition mask 120. The first areamay be defined by an entire length of the distal end 120_e at which theclamping groove 122 does not overlap the clamping groove 122 in thelength direction of the deposition mask 120.

In detail, the dummy pattern unit 123 may overlap at least a portion ofthe clamping groove 122 with respect to the first direction (Y axisdirection). Also, the clamping groove 122 and the dummy pattern unit 123may each be provided in plural respectively spaced apart from each otheralong the second direction (X axis direction). The number of theclamping grooves 122 and the number of the dummy pattern units 123 maycorrespond to each other. Structures of the clamping groove 122 and thedummy pattern unit 123 will be explained in detail below.

Referring back to FIG. 2, in the deposition mask 120P according to theprior art, a dummy pattern unit 123P is disposed as a single dummypattern unit including a plurality of dummy pattern holes 123P_h, a(deposition) pattern unit 121P is disposed as a single pattern unitincluding a plurality of deposition pattern holes 121P_h through which adeposition material passes, and a clamping groove 122P is defined. Theabove-described structure of the dummy pattern unit 123P and the patternunit 121P may be provided to reduce or effectively prevent deformationof the pattern unit 121P due to the tensile force (F) applied to thedeposition mask 120P. In detail, the dummy pattern unit 123P between thepattern unit 121P and the respective distal ends 120P_e has a same widthas the pattern unit 121P. Thus, the dummy pattern unit 123P may functionto absorb the tensile force transmitted to the pattern unit 121P throughthe distal ends 120P_e during application of the tensile force (F).

However, the dummy pattern unit 123P does not reduce a wrinklephenomenon in which different portions of the deposition mask 120P havedifferent heights with respect to a thickness direction (Z axisdirection) of the deposition mask 120P.

In contrast, the deposition mask 120 of FIGS. 1 and 3 according to oneor more exemplary embodiments of the invention may include the dummypattern units 123 spaced apart from each other, which partially overlapthe clamping grooves 122 in the length direction of the deposition mask120, respectively, and thus, may reduce the wrinkle phenomenon.

In the conventional deposition mask 120P of FIG. 2, the distal ends120P_e which are respectively clamped by the clamp when the depositionmask 120 is extended, include a total of three areas, for example, aleftmost area, a rightmost area and a center area along the second(width) direction of the deposition mask 120P. The left, right andcenter areas generally correspond to portions of the distal ends 120P_efrom which the force (F) is shown extended. The tensile force (F, whichis applied to the leftmost area and the rightmost area of the distalends 120P_e, is transmitted to a main body of the deposition mask 120Pat which the pattern unit 121P is arranged. However, the tensile force,which is applied to the center area (that is, the reference region “A”),is absorbed by the dummy pattern unit 123P at or near the referenceregion “A”. Accordingly, the tensile force is significantly variablewith respect to the second direction in the deposition mask 120P andthus, wrinkles are formed in the deposition mask 120P.

In contrast, in the deposition mask 120 according to one or moreexemplary embodiment of the invention as illustrated in FIG. 3, thedummy pattern unit 123 does not exist in the center area correspondingto the reference region “A.” Thus, the tensile force (F) applied to thecenter area of the deposition mask 120, which is the same as the tensileforce (F) applied to the left area and the right area of the depositionmask 120, is applied to the pattern unit 121 of the deposition mask 120.That is, the tensile force is more uniformly distributed to thedeposition mask 120 than the conventional deposition mask 120P of FIG.2, with respect to the second direction. Accordingly, in the depositionmask 120 having a structure as illustrated in FIG. 3, the tensile forcegenerated by the clamp is more uniformly distributed to the entiredeposition mask 120, and thus, the wrinkle phenomenon, which isgenerated during extending the deposition mask 120, may be reduced oreffectively prevented.

Effects on the above-described improvement of the wrinkle phenomenonwill be described with reference to FIGS. 4 and 5.

FIG. 4 is a graph comparatively illustrating heights of wrinkles of theconventional deposition mask 120P of FIG. 2, and FIG. 5 is a graphcomparatively illustrating heights of wrinkles of the deposition mask120 of FIG. 3 according to one or more exemplary embodiment of theinvention.

Referring to FIG. 4, a peak-to-peak value of the wrinkles is 701micrometers (μm) in the conventional deposition mask 120P which includesthe dummy pattern unit 123P having a total width corresponding to atotal width of the pattern unit 121P as illustrated in FIG. 2.

However, referring to FIG. 5, a peak-to-peak value of the wrinkles is582 μm in the deposition mask 120 which includes the dummy pattern unit123 partially overlapping the clamping groove 122 with respect to thefirst direction and having a width less than that of the pattern unit121, as illustrated in FIG. 3. The wrinkle phenomenon of the depositionmask 120 may be improved by about 17%, compared to the wrinklephenomenon of the conventional deposition mask 120P.

FIGS. 4 and 5 illustrate experimental data to compare wrinkles generatedby the structure of the conventional deposition mask 120P of FIG. 2 andthe structure of an exemplary embodiment of the deposition mask 120 ofFIG. 3, to each other. The experimental data to analyze the wrinklephenomenon of the deposition mask 120 as illustrated in FIG. 5 is basedon a structure of the deposition mask 120 in which the dummy patternunit 123 collectively includes two individual dummy pattern unitsarranged separated from each other in the second direction as oneexample. However, the dummy pattern unit 123 may collectively include adifferent number of individual dummy pattern units separated from eachother in the deposition mask 120, and thus, the value of thepeak-to-peak of the wrinkles may be changed. Nevertheless, the wrinklesof one or more exemplary embodiment of the deposition mask 120 accordingto the invention may be significantly reduced as compared to theconventional deposition mask, when the deposition mask 120 includesplural individual dummy pattern units 123 separated from each other tocorrespond to a number of clamping grooves 122.

Accordingly, the deposition mask 120 having a structure as describedabove may effectively improve the wrinkle phenomenon. Moreover, a gap,which is formed between the deposition mask 120 and the substrate in thedeposition process, may be reduced. Accordingly, the shadow phenomenonmay be improved, and thus, the display defect may be reduced.

FIG. 6 is a top plan view illustrating another exemplary embodiment of adeposition mask according to the invention. The deposition mask of FIG.6 is a modified embodiment of the deposition mask 120 of FIG. 3.

Referring to FIG. 6, the dummy pattern unit 123 may be disposed inplural arranged along the first direction. In more detail, between asame clamping groove 122 and the pattern unit 121, a collective dummypattern unit includes in the first direction of the deposition mask 120,a first pattern unit (upper 123) and a second pattern unit (lower 123)spaced apart from each other. A solid portion of the deposition mask 120in which dummy pattern holes 123_h are not formed, is disposed betweenthe first and second pattern units (upper and lower 123) spaced apartfrom each other. Within each of the first pattern unit (upper 123) andthe second pattern unit (lower 123), a plurality of dummy pattern holes123_h are arranged in the first direction of the deposition mask 120with a horizontal dummy solid portion of the deposition maskrespectively disposed between adjacent dummy pattern holes 123_h in thefirst direction (e.g., to form a mesh-like pattern along with verticaldummy solid portions). In the first direction of the deposition mask120, a length of the solid portion between the first and second patternunits (upper and lower 123) spaced apart from each other is greater thana length of the dummy solid portion respectively disposed between theadjacent dummy pattern holes 123_h.

Although FIG. 6 illustrates two dummy pattern units 123 arranged alongthe first direction, the present disclosure is not limited thereto. Thatis, the number of the dummy pattern units 123 of FIG. 6 is an exemplaryembodiment of the invention. In an alternative exemplary embodiment,More than two of the dummy pattern unit 123 may be disposed in plural inthe first direction, for example, three, four, etc.

In detail, the number of the dummy pattern units 123 may be changedaccording to a size of the deposition mask 120. The size of thedeposition mask 120 may be changed according to a size of a displayapparatus to be manufactured therewith, and thus, the number of thedummy pattern units 123 may also be changed. Although the number of thedummy pattern units 123 is changed, the number of the clamping grooves122 of the deposition mask 120 corresponds to the number of the dummypattern units 123 of the deposition mask 120 arranged in a single linein the first direction. Moreover, at least a portion of the clampinggroove 122 overlaps at least a portion of the corresponding dummypattern unit 123 with respect to the first direction.

FIG. 7 is a top plan view illustrating still another embodiment of thedeposition mask according to the invention. The deposition mask of FIG.7 is a further modified embodiment of the deposition mask 120 of FIG. 3.

Referring to FIG. 7, the deposition mask 220 may include a depositionpattern unit 221 (hereinafter referred to as a “pattern unit 221”), aclamping groove 222 provided in plural and a dummy pattern unit 223provided in plural.

The deposition mask 120 of FIG. 3 or FIG. 6 may be considered a unitdeposition mask. Referring to FIG. 7, a deposition mask 220 may includea structure in which a plurality of deposition masks 120 of FIG. 3 (orFIG. 6) are effectively arranged or attached to each other as onesingle, unitary body. That is, the deposition mask 220 may include anyof various structures of a deposition mask as long as a portion of aclamping groove 222 and a corresponding dummy pattern unit 223 overlapeach other along the first direction, and the number of the clampinggrooves 222 and the number of the dummy pattern units 223 arranged inthe second direction correspond to each other, as described above.Reference numerals 220_e, 223_h, 240, 221_h, and 221 of FIG. 7correspond to reference numerals 120_e, 123_h, 140, 121_h, and 121 ofFIG. 3, respectively, such that repeated description of referencenumerals 120_e, 123_h, 140, 121_h, and 121 are omitted for convenience.

FIG. 8 is a perspective view schematically illustrating an exemplaryembodiment of a deposition mask frame assembly 100 including thedeposition mask 10 of FIG. 1.

Referring to FIGS. 1 and 8, the deposition mask frame assembly 100includes the frame 110, a deposition mask 120, and a supporting member130 (hereinafter referred to as a “support stick 130”). The depositionmask frame assembly 100 may include a plurality of deposition masks 120,and a plurality of support sticks 130.

The frame 110 may include a metal or synthetic resin, and may includeone or more openings having an overall rectangular shape in the top planview. However, the invention is not limited thereto. The opening mayhave various shapes in the top plan view, for example, a circular shape,a hexagonal shape, etc. For convenience, an exemplary embodiment inwhich the opening having the rectangular shape in the top plan view,will be explained hereinafter.

The frame 110 may include a pair of first frame members 111 defininglengths thereof extended along a second direction (X axis direction) anda pair of second frame members 112 connected to the corresponding firstframes 111 and defining lengths thereof extended along the firstdirection (Y axis direction). The first frame members 111 and the secondframe members 112 form a main opening of the frame 110.

The support stick 130 defines a length thereof extended in the seconddirection (X axis direction), divides the main opening in tosub-openings, and is coupled to the frame 110. Both of opposing ends inthe length direction of the support stick 130 may be inserted into acorresponding groove 113 of the second frame members 112 and may becoupled thereto. The support stick 130 may be coupled to the groove 113by welding or by an adhesive.

A structure of the deposition mask 120 of FIG. 8 may be same as orsimilar to a structure of the deposition mask 120 of FIGS. 1 and 3 or220 in FIG. 7, and thus, the structure of the deposition mask 120 ofFIG. 8 will be briefly described since the descriptions of the structureof the deposition mask 120 of FIG. 8 correspond to descriptions of thestructure of the deposition mask 120 of FIGS. 1 and 3 and 220 in FIG. 7.

As described above, the deposition mask 120 may include a pattern unit121 including a plurality of pattern holes 121_h, and also include adummy pattern unit 123 respectively between the pattern unit 121 and thedistal ends 120_e of the deposition mask 120. The dummy pattern unit 123may be provided in plural to define an overall dummy pattern unitincluding a plurality of individual dummy pattern units 123 arrangedalong the second direction. A first extension state of the dummy patternunit 123, that is, an extension state of the reference region “B” ofFIG. 3, may be different from a second extension state of the dummypattern unit 123, that is, an extension state of the reference region“A” of FIG. 3.

The support stick 130 may support a plurality of the deposition masks120 on the frame 110. Moreover, the support stick 130 may cover aportion of the deposition mask 120 at the pattern unit 121. Accordingly,a deposition material does not pass through the portion of thedeposition mask 120 which is covered by the support stick 130, and thedeposition material may pass through another portion of the depositionmask 120 which is not covered by the support stick 130. Furthermore, thesupport stick 130 may disperse a weight of the deposition mask 120 onthe frame 110 and may prevent sagging of the deposition mask 120 fromthe frame 110.

The support stick 130 may include a relatively low magnetic material. Inan exemplary embodiment, for example, the support stick 130 may includesteel use stainless (“SUS”). A surface of the support stick 130 maycontact the deposition mask 120.

If the support stick 130 includes a relatively high magnetic material, astrong attraction force may be generated between the support stick 130and an electrostatic chuck (180 of FIG. 9A) which urges a portion of thedeposition mask 120 at the support stick 130 towards the electrostaticchuck. When the deposition mask 120 is urged towards the electrostaticchuck, a gap is generated between a substrate (11 of FIG. 9A) and thedeposition mask 120 or the pattern unit 121 of the deposition mask 120is not aligned with the substrate 11. Accordingly, in one or moreexemplary embodiment, the support stick 130 may include a relatively lowmagnetic material so that the substrate (11 of FIG. 9A) and thedeposition mask 120 is in close contact with each other, and the patternunit 121 of the deposition mask 120 is precisely aligned with thesubstrate 11.

FIG. 9A is a cross-sectional view schematically illustrating anexemplary embodiment of a manufacturing apparatus 10 including thedeposition mask frame assembly 100 of FIG. 8 for manufacturing a displayapparatus. FIG. 9B is an enlarged cross-sectional view of a portion P ofthe manufacturing apparatus including the deposition mask frame assemblyof FIG. 8;

The manufacturing apparatus 10 may include a deposition source 200, achamber 161 in which the deposition mask frame assembly 100 is disposedand deposition material is deposited on a substrate, a supporter 162, anelectromagnetic chuck 180 and a vision unit 182. Here, the depositionmask frame assembly 100 of FIG. 9A is the same as the deposition maskframe assembly of FIG. 8. Accordingly, descriptions of the depositionmask frame assembly 100 of FIG. 9A will be omitted since thedescriptions of the deposition mask frame assembly 100 of FIG. 9Acorrespond to descriptions of the deposition mask frame assembly 100 ofFIG. 8.

The deposition source 200 may be arranged to face the deposition maskframe assembly 100, and a portion of the deposition source 200 may beopen to face the deposition mask frame assembly 100. Deposition materialmay be exposed outside the deposition source 200 at the open facethereof. Moreover, the deposition source 200 may include a heater (notillustrated) to heat the deposition material.

The deposition material may be received inside the deposition source200. Here, the deposition material may include one or more of aninorganic material, a metal, and an organic material as a material whichis vaporized or gasified. However, as an exemplary embodiment, thedeposition material as the organic material, will be describedhereinafter.

An airtight space is formable inside the chamber 161, and a portion ofthe chamber 161 may be openable such as to insert and remove thedeposition mask assembly 100 and/or elements thereof from the chamber161. Here, a gate valve 161 a may be installed at the openable portionof the chamber 161 and thus, the gate valve 161 a may close or open theportion of the chamber 161 for insertion or removal of the depositionmask assembly 100 and/or elements thereof.

The deposition mask frame assembly 100 may be placed over the supporter162. Here, the supporter 162 may rotate and/or linearly move thedeposition mask frame assembly 100 within the chamber 161.

The electromagnetic chuck 180 may align the substrate 11 relative to thedeposition mask frame assembly 100, such as disposing the substrate 11on the deposition mask frame assembly 100 within the chamber 161. Theelectromagnetic chuck 180 may hold the substrate 11 by using anelectromagnetic force such as when the substrate 11 is separated fromthe deposition mask assembly 100. The electromagnetic chuck 180 mayalign the substrate 11 over the deposition mask frame assembly 100within the chamber 161. Here, by using the vision unit 182, thesubstrate 11 may be precisely aligned over the deposition mask frameassembly 100 within the chamber 161.

The manufacturing apparatus 10 may deposit the deposition material onthe substrate 11 after supporting the substrate 11 as described above.In another exemplary embodiment, the deposition material may bedeposited on the substrate 11 while the substrate 11 and the depositionsource 200 relatively move with respect to each other. However, anexemplary embodiment in which the deposition material is deposited onthe substrate 11 while the substrate 11 is supported in a staticposition within the manufacturing apparatus 10, will be describedhereinafter, for convenience.

A pressure controller 190 may be installed to be in communication withthe chamber 161. The pressure controller 190 may include a connectionpipe 191 connected to the chamber 161 and a pump 192 which is installedat the connection pipe 191.

The manufacturing apparatus 10 as described above may form an organiclayer, an inorganic layer or a metal layer on the substrate 11. However,an exemplary embodiment in which the manufacturing apparatus 10 formsthe organic layer on the substrate 11, will be described hereinafter,for convenience.

In an operation of the manufacturing apparatus 10, the substrate 11 andthe deposition mask frame assembly 100 are inserted into an inside ofthe chamber 161 and then supported by the supporter 162 within thechamber 161.

Locations of the substrate 11 and the deposition mask frame assembly 100are determined by using the vision unit 182, and then the substrate 11and the deposition mask frame assembly 100 may be aligned with eachother by using the electromagnetic chuck 180. In an exemplaryembodiment, the vision unit 182 may include a camera to photograph thesubstrate 11 and the deposition mask frame assembly 100, and suchphotograph may be used to determine positions of elements within thechamber 161.

The electromagnetic chuck 180 may hold the substrate 11 and thedeposition mask frame assembly 100 relative to each other by using theelectromagnetic force generated by the electromagnetic chuck 180. Here,the electromagnetic chuck 180 may reduce a gap between the substrate 11and the deposition mask frame assembly 100 so that the substrate 11 andthe deposition mask frame assembly 100 are in close contact with eachother within the chamber 161.

After the substrate 11 and the deposition mask frame assembly 100 arealigned with each other, the deposition material may be vaporized orgasified by operating the deposition source 200. Here, the depositionmaterial may pass from the deposition source 200 (dotted lines in FIG.9A) through the plurality of pattern holes 121_h of the plurality ofdeposition masks 120 of the deposition mask frame assembly 100 and thenmay be deposited on the substrate 11. Thereafter, the substrate 11, onwhich a depositing process is completed by having the depositionmaterial thereon, is taken out from the chamber 161 and then a followingprocess may be performed on the substrate 11.

Referring to FIG. 9B, at portion P of the manufacturing apparatus 10including the deposition mask frame assembly 100 therein, the frame 110and the deposition mask 120 may be coupled to each other at a weldingportion 140 of the deposition mask 120. The welding portion 140 and thedummy pattern unit 123 along with the dummy pattern holes 123_h thereof,overlap the supporter 162. Since the dummy pattern unit 123 along withthe dummy pattern holes 123_h are each overlapped by the supporter 162,deposition material does not pass through the dummy pattern holes 123_hto the substrate 11. That is, the dummy pattern unit 123 does notparticipate in the process of depositing material onto the substrate 11.The distal ends (120_e of FIGS. 3 and 6 and 220_e) of the depositionmask 120 in FIGS. 9A and 9B may be defined as a portion of thedeposition mask 120 which is disposed to overlap the frame 110 and/orthe supporter 162, but the invention is not limited thereto.

FIG. 10 is a top plan view illustrating an exemplary embodiment of adisplay apparatus 20 which is manufactured by the manufacturingapparatus 10 of FIG. 9A and a method of manufacturing the displayapparatus using the manufacturing apparatus 10, according to theinvention, and FIG. 11 is a cross-sectional view taken along line XI-XIof FIG. 10.

Referring to FIGS. 10 and 11, the display apparatus 20 may include adisplay area DA which is defined for a substrate 21, and a non-displayarea (not illustrated) at an outer circumference of the display area DA.Planar areas of the non-display area and the display area DA may definean entirety of a planar area of the substrate 21. A light-emitting unitD is arranged in the display area DA, and power wirings (notillustrated) are arranged in the non-display area to be connected to thelight-emitting unit D. A pad area C to which signals and/or power isapplied to the substrate 21 and elements thereon, may be arranged in thenon-display area.

The display apparatus 20 may include the substrate 21 and the emission Ddisposed on the substrate 21. The display apparatus 20 may furtherinclude an encapsulating layer E over an upper portion of thelight-emitting unit D. Here, the substrate 21 may include a plasticmaterial or a metal material, such as steel use stainless (“SUS”),titanium (Ti), etc. Also, the substrate 21 may include polyimide (“PI”).

The light-emitting unit D may be disposed over the substrate 21, thatis, on an upper surface thereof. Here, the light-emitting unit D mayinclude a thin film transistor TFT, a passivation film 27 covering thethin film transistor TFT, and an organic light-emitting device (“OLED”)28 over the passivation film 27.

Here, the substrate 21 may include a glass material. However, theinvention is not limited thereto. The substrate 21 may include a plasticmaterial or a metal such as SUS, Ti, etc. Also, the substrate 21 mayinclude the PI. For convenience, an exemplary embodiment in which thesubstrate 21 includes a glass material, will be explained in detailhereinafter.

A buffer layer 22 may be over the upper surface of the substrate 21 andmay include an organic compound and/or an inorganic compound. The bufferlayer 22 may include silicon oxide (SiOx) where x≧1 or silicon nitride(SiNx) where x≧1.

An active layer 23 is disposed or formed as a collection of a pluralityof patterns which are arranged over the buffer layer 22. A gateinsulating layer 24 is disposed or formed over the active layer 23 tobury the active layer 23. The active layer 23 may include a source area23-1, a drain area 23-3, and a channel area 23-2 between the source area23-1 and the drain area 23-3.

The active layer 23 may include various materials. In an exemplaryembodiment, for example, the active layer 23 may include an inorganicsemiconductor material, such as amorphous silicon or crystal silicon. Inanother exemplary embodiment, the active layer 23 may include an organicsemiconductor material. However, an exemplary embodiment in which theactive layer 23 includes amorphous silicon, will be explained in detailhereinafter.

The active layer 23 may be disposed or formed by forming a preliminarylayer of amorphous silicon over the buffer layer 22, crystallizing thepreliminary layer of amorphous silicon to form a polycrystalline, andpatterning the polycrystalline. The active layer 23 may include thesource area 23-1 and the drain area 23-3 which are formed by doping asame material layer for forming the active layer 23 with impuritiesaccording to a kind of the thin film transistor TFT, such as a drivingthin film transistor (not illustrated) and a switching thin filmtransistor (not illustrated). The source area 23-1, the drain area 23-3and the channel area 23-2 may be formed from a same material layer forforming the active layer 23, where the channel area 23-2 portion thereofis not doped or doped differently from the source and drain areas 23-1and 23-3.

A gate electrode 25 is disposed or formed over the gate insulating layer24 to correspond to the active layer 23, and then an interlayerinsulating layer 26 is disposed or formed to bury the gate electrode 25.

A contact hole H1 is disposed or formed in plural extended through theinterlayer insulating layer 26 and the gate insulating layer 24 toexpose the source area 23-1 and the drain area 23-3, respectively. Asource electrode 27-1 and a drain electrode 27-2 are disposed or formedover the interlayer insulating layer 26 and contact the source area 23-1and the drain area 23-3, respectively, at the contact holes H1.

The passivation film 27 is disposed or formed over the thin filmtransistor TFT, and a pixel electrode 28-1 of the organic light-emittingdevice OLED is disposed or formed over the passivation film 27. Thepixel electrode 28-1 contacts the drain electrode 27-2 of the thin filmtransistor TFT at a via hole H2 which is disposed or formed extendedthrough the passivation film 27. The passivation film 27 may include aninorganic material, an organic material, a single layer, or a multilayerhaving two or more layers. The passivation film 27 may be aplanarization film having a flat upper film surface regardless of acurved lower film surface thereof. However, alternatively, thepassivation film 27 may have a curved upper film surface according tothe curved lower film surface. The passivation film 27 may include atransparent insulating material to attain resonance effects.

A pixel defining film 29 is disposed or formed to cover the pixelelectrode 28-1 and the passivation film 27. The pixel defining film 29includes an organic material and/or an inorganic material. An opening isdisposed or formed in the pixel defining film 29 to expose the pixelelectrode 28-1 to outside the pixel defining film 29.

An intermediate layer 28-2 and an opposite electrode 28-3 are disposedor formed over the pixel electrode 28-1.

The pixel electrode 28-1 may function as an anode and the oppositeelectrode 28-3 may function as a cathode of the OLED 28. In an exemplaryembodiment, t is possible that polarities of the pixel electrode 28-1and the opposite electrode 28-3 may be reversed.

The pixel electrode 28-1 and the opposite electrode 28-3 may beinsulated from each other by the intermediate layer 28-2, and voltageswith different polarities are applied to the intermediate layer 28-2such that light is emitted from the intermediate layer 28-2 as anorganic emission layer.

The intermediate layer 28-2 may include the organic emission layer. Inanother exemplary embodiment, the intermediate layer 28-2 may includethe organic emission layer and additionally include at least one of ahole injection layer (“HIL”), a hole transport layer (“HTL”), anelectron transport layer (“ETL”), and an electron injection layer(“EIL”). However, the present disclosure is not limited thereto. Theintermediate layer 28-2 may include the organic emission layer andadditionally include various functional layers (not illustrated).

Here, the intermediate layer 28-2 of the display apparatus may be formedan apparatus (not illustrated) to manufacture the display apparatus 20described above. In an exemplary embodiment, the intermediate layer 28-2may be precisely formed by one or more exemplary embodiment of themanufacturing apparatus 10 of FIGS. 9A and 9B and a method ofmanufacturing the display apparatus using the manufacturing apparatus10, according to the invention.

A unit pixel may be defined in plural in the display area DA of thesubstrate 21. An image may be displayed by the unit pixel. The unitpixel may include a plurality of sub-pixels, and the plurality ofsub-pixels may respectively emit various different colors of lightwithin the unit pixel. In an exemplary embodiment, for example, theplurality of sub-pixels may include sub-pixels respectively emitting ared color light, a green color light and a blue color light orsub-pixels respectively emitting the red color light, the green colorlight, the blue color light and a white color light.

The encapsulating layer E may include a plurality of inorganic layers ormay include an inorganic layer and an organic layer.

The organic layer of the encapsulating layer E may include a polymer.The organic layer of the encapsulating layer E may include a single filmor a stack film including at least one of polyethylene terephthalate,polyimide, polycarbonate, epoxy, polyethylene, and polyacrylate. Theorganic layer of the encapsulating layer E may include polyacrylate. Theorganic layer of the encapsulating layer E may include adiacrylate-based monomer or a polymerized monomer compound including thediacrylate-based monomer. A monoacrylate-based monomer may be added tothe monomer compound. Also, a photoinitiator, such asDiphenyl(2,4,6-trimethylbenzoyl)phosphine oxide (TPO), may be added tothe monomer compound. However, the present disclosure is not limitedthereto.

The inorganic layer of the encapsulating layer E may include a singlefilm or a stack film, which may include metal oxide or metal nitride.The inorganic layer of the encapsulating layer E may include one ofsilicon nitride (SiNx), aluminum oxide (Al2O3), silicon oxide (SiO2),and titanium oxide (TiO2).

An uppermost layer of the encapsulating layer E may include an inorganiclayer to prevent introduction of moisture into the organiclight-emitting device (“OLED”).

The encapsulating layer E may include at least one sandwiched structurein which at least one organic layer is inserted into at least twoinorganic layers. In another embodiment, the encapsulating layer E mayinclude at least one sandwiched structure in which at least oneinorganic layer is inserted into at least two organic layers. In anotherembodiment, the encapsulating layer E may include at least onesandwiched structure in which at least one organic layer is interposedbetween at least two inorganic layers, and at least one sandwichedstructure in which at least one inorganic layer is interposed between atleast two organic layers.

The encapsulating layer E may include a first inorganic layer, a firstorganic layer, and a second inorganic layer, which are disposed in orderfrom an upper portion of the organic light-emitting device (“OLED”).

In another embodiment, the encapsulating layer E may include a firstinorganic layer, a first organic layer, a second inorganic layer, asecond organic layer, and a third inorganic layer, which are disposed inorder from the upper portion of the organic light-emitting device(“OLED”).

In another embodiment, the encapsulating layer E may include a firstinorganic layer, a first organic layer, a second inorganic layer, asecond organic layer, a third inorganic layer, a third organic layer,and a fourth inorganic layer, which are disposed in order from the upperportion of the organic light-emitting device (“OLED”).

A halogenated metal layer including lithium fluoride (LiF) may be addedbetween the organic light-emitting device (“OLED”) and the firstinorganic layer of the encapsulating layer E. the halogenated metallayer may prevent damage of the organic light-emitting device (“OLED”)during forming the first inorganic layer by using a sputtering method.

An area of the first organic layer may be smaller than an area of thesecond inorganic layer, and an area of the second organic layer may besmaller than an area of the third inorganic layer.

Accordingly, since the display apparatus 20 includes the intermediatelayer 28-2 having a precisely-formed pattern and the intermediate layer28-2 is deposited and formed at an accurate location of the displayapparatus 20 by one or more exemplary embodiment of the manufacturingapparatus 10 of FIGS. 9A and 9B and a method of manufacturing thedisplay apparatus using the manufacturing apparatus 10, according to theinvention, a precise image may be realized in the display apparatus 20.Moreover, a constant pattern among unit pixels of the display apparatus20 may be maintained by one or more exemplary embodiment of themanufacturing apparatus 10 of FIGS. 9A and 9B and a method ofmanufacturing the display apparatus using the manufacturing apparatus10, according to the invention such that uniform quality within thedisplay apparatus 20 by continuous productions when the intermediatelayer 28-2 is repeatedly deposited on the substrate 21 in forming thedisplay apparatus 20.

It should be understood that embodiments described herein should beconsidered in a descriptive sense only and not for purposes oflimitation. Descriptions of features within each embodiment shouldtypically be considered as available for other similar features in otherembodiments.

While one or more embodiments have been described with reference to thefigures, it will be understood by those of ordinary skill in the artthat various changes in form and details may be made therein withoutdeparting from the spirit and scope as defined by the following claims.

What is claimed is:
 1. A deposition mask for depositing a depositionmaterial on a substrate, comprising: a deposition pattern unitcomprising a plurality of deposition pattern holes through which thedeposition material passes to the substrate; and a distal end extendedin a first direction of the deposition mask from the deposition patternunit to a distal edge of the deposition mask, the distal end comprising:a clamping groove open at the distal edge of the deposition mask; and adummy pattern unit disposed between the clamping groove and thedeposition pattern unit in the first direction of the deposition mask;wherein the clamping groove and the dummy pattern unit are provided inplural along a second direction crossing the first direction of thedeposition mask, and in the first direction of the deposition mask, aportion of each clamping groove overlaps a corresponding dummy patternunit, in the second direction of the deposition mask, the number of theclamping grooves and the number of the dummy pattern units correspond toeach other, an area of the distal end at which the portion of the distalend does not overlap the corresponding dummy pattern unit defines afirst area of the distal end to which a clamp is applied, and an area ofthe distal end at which the portion of each clamping groove overlaps thecorresponding dummy pattern unit defines a second area of the distalend.
 2. The deposition mask of claim 1, wherein the dummy pattern unitcomprises a plurality of dummy pattern holes, and a shape of one of theplurality of dummy pattern holes corresponds to a shape of one of theplurality of the deposition pattern holes.
 3. The deposition mask ofclaim 1, wherein the dummy pattern unit comprises a plurality of dummypattern holes, and a shape of one of the plurality of dummy patternholes is different from a shape of one of the plurality of thedeposition pattern holes.
 4. The deposition mask of claim 1, wherein inthe first direction of the deposition mask, the dummy pattern unitcomprises a first dummy pattern unit and a second dummy pattern unitspaced apart from each other, each of the first and second dummy patternunits comprising a plurality of dummy pattern holes.
 5. An apparatus formanufacturing a pattern on a substrate of a display apparatus, theapparatus comprising: a deposition mask frame assembly facing thesubstrate; and a deposition source facing the deposition mask frameassembly to dispose the deposition mask frame assembly between thesubstrate and the deposition source, wherein the deposition mask frameassembly comprises: a frame comprising an opening at a center portionthereof; a deposition mask which is installed on the frame to face thesubstrate, a length of the deposition mask extended in a firstdirection; and a support of which a length thereof extends in a seconddirection crossing the first direction and across the opening of theframe, the support overlapping a portion of the deposition mask andsupporting the deposition mask which is installed on the frame, whereinthe deposition mask is extendable along the first direction thereof by aforce applied thereto by a clamp attached to the deposition mask, thedeposition mask comprising: a deposition pattern unit comprising aplurality of deposition pattern holes through which a depositionmaterial for forming the pattern passes to the substrate; and a distalend to which the clamp is attached, the distal end extended in the firstdirection of the deposition mask from the deposition pattern unit to adistal edge of the deposition mask, the distal end comprising: aclamping groove open at the distal edge of the deposition mask; and adummy pattern unit disposed between the clamping groove and thedeposition pattern unit in the first direction of the deposition mask,wherein the clamping groove and the dummy pattern unit are provided inplural along the second direction, and in the first direction of thedeposition mask,  a portion of each clamping groove overlaps acorresponding dummy pattern unit,  in the second direction of thedeposition mask,  the number of the clamping grooves and the number ofthe dummy pattern units correspond to each other,  an area of the distalend at which the portion of distal end does not overlap thecorresponding dummy pattern unit defines a first area of the distal endto which a clamp is applied, and  an area of the distal end at which theportion of each clamping groove overlaps the corresponding dummy patternunit defines a second area of the distal end.
 6. The apparatus of claim5, wherein the dummy pattern unit comprises a plurality of dummy patternholes, and a shape of one of the plurality of dummy pattern holescorresponds to a shape of one of the plurality of the deposition patternholes.
 7. The apparatus of claim 5, wherein the dummy pattern unitcomprises a plurality of dummy pattern holes, and a shape of one of theplurality of dummy pattern holes is different from a shape of one of theplurality of the deposition pattern holes.
 8. The apparatus of claim 5,wherein in the first direction of the deposition mask, the dummy patternunit comprises a first dummy pattern unit and a second dummy patternunit spaced apart from each other, each of the first dummy pattern unitand second dummy pattern unit comprising a plurality of dummy patternholes.
 9. The apparatus of claim 5, wherein the deposition mask frameassembly further comprises a welding portion which couples the frame andthe deposition mask to each other, and the welding portion is disposedat the distal end of the deposition mask.
 10. The apparatus of claim 9,wherein in the first direction of the deposition mask, the weldingportion is disposed between the pattern unit and the dummy pattern unit.11. A method of manufacturing a display apparatus having a pattern on asubstrate, the method comprising: inserting the substrate and adeposition mask assembly into an inside of a deposition chamber;aligning the substrate and the deposition mask frame assembly with eachother; and depositing on the substrate a deposition material for formingthe pattern, by ejecting the deposition material from a depositionsource and passing the ejected deposition material through thedeposition mask frame assembly to the substrate, wherein the depositionmask frame assembly comprises: a frame comprising an opening at a centerportion thereof; a deposition mask which is installed on the frame toface the substrate, a length of the deposition mask extended in a firstdirection; and a support of which a length thereof extends in a seconddirection crossing the first direction and across the opening of theframe, the support overlapping a portion of the deposition mask andsupporting the deposition mask which is installed on the frame, whereinthe deposition mask is extendable along the first direction thereof by aforce applied thereto by a clamp attached to the deposition mask, thedeposition mask comprising: a deposition pattern unit comprising aplurality of deposition pattern holes, through which the ejecteddeposition material passes to the substrate; and a distal end to whichthe clamp is attached, the distal end extended in the first direction ofthe deposition mask from the deposition pattern unit to a distal edge ofthe deposition mask, the distal end comprising: a clamping groove openat the distal edge of the deposition mask; and a dummy pattern unitdisposed between the clamping groove and the deposition pattern unit inthe first direction of the deposition mask, and wherein the clampinggroove and the dummy pattern unit are provided in plural along thesecond direction; and in the first direction of the deposition mask,  aportion of each clamping groove overlaps a corresponding dummy patternunit,  in the second direction of the deposition mask, the number of theclamping grooves and the number of the dummy pattern units correspond toeach other,  an area of the distal end at which the portion of thedistal end does not overlap the corresponding dummy pattern unit definesa first area of the distal end to which a clamp is applied, and  an areaof the distal end at which the portion of each clamping groove overlapsthe corresponding dummy pattern unit defines a second area of the distalend.
 12. The method of claim 11, wherein the dummy pattern unitcomprises a plurality of dummy pattern holes, and a shape of one of theplurality of dummy pattern holes corresponds to a shape of one of theplurality of the deposition pattern holes.
 13. The method of claim 11,wherein the dummy pattern unit comprises a plurality of dummy patternholes, and a shape of one of the plurality of dummy pattern holes isdifferent from a shape of one of the plurality of the deposition patternholes.
 14. The method of claim 11, wherein in the length direction ofthe deposition mask, the dummy pattern unit comprises a first dummypattern unit and a second dummy pattern unit spaced apart from eachother, each of the first and second dummy pattern units comprising aplurality of dummy pattern holes.
 15. The method of claim 11, whereinthe deposition mask frame assembly further comprises a welding portionwhich couples the frame and the deposition mask to each other, and thewelding portion is disposed at the distal end of the deposition mask.16. The method of claim 15, wherein in the first direction of thedeposition mask, the welding portion is disposed between the patternunit and the dummy pattern unit.